Micromachined bilayer unit of engineered tissues

ABSTRACT

Methods and materials for making an apparatus which duplicates the functionality of a physiological system is provided.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application is a division of U.S. application Ser. No. 10/983,213,filed Nov. 5, 2004, issued as U.S. Pat. No. 7,776,021, which is acontinuation-in-part of U.S. application Ser. No. 10/187,247, filed Jun.28, 2002, which claims priority to U.S. provisional patent applicationSer. No. 60/367,675, filed Mar. 25, 2002. The disclosures of each ofthese applications are incorporated by reference herein in theirentireties.

Reference is made to U.S. application Ser. No. 10/038,891, filed Jan. 2,2002, which claims priority to U.S. patent application Ser. No.60/259,283, filed Jan. 2, 2001. Reference is made to U.S. applicationSer. No. 09/560,480, filed Apr. 28, 2000, which claims priority to U.S.patent application Ser. No. 60/131,930 filed Apr. 30, 1999, and U.S.patent application Ser. No. 60/165,329, filed Nov. 12, 1999. Thedisclosures of each of these applications are incorporated by referenceherein in their entireties.

INCORPORATION BY REFERENCE

Each of the foregoing applications and patents and articles, and eachdocument cited or referenced in each of the foregoing applications andpatents and articles, including during the prosecution of each of theforegoing applications and patents (“application and article citeddocuments”), and any manufacturer's instructions or catalogues for anyproducts cited or mentioned in each of the foregoing applications andpatents and articles and in any of the application and article citeddocuments, are hereby incorporated herein by reference. Furthermore, alldocuments cited in this text, and all documents cited or referenced indocuments cited in this text, and any manufacturer's instructions orcatalogues for any products cited or mentioned in this text or in anydocument hereby incorporated into this text, are hereby incorporatedherein by reference. Documents incorporated by reference into this textor any teachings therein can be used in the practice of this invention.Documents incorporated by reference into this text are not admitted tobe prior art. Furthermore, authors or inventors on documentsincorporated by reference into this text are not to be considered to be“another” or “others” as to the present inventive entity and vice versa,especially where one or more authors or inventors on documentsincorporated by reference into this text are an inventor or inventorsnamed in the present inventive entity.

STATEMENT REGARDING GOVERNMENT INTEREST

The United States government has certain rights in this invention byvirtue of grant number DAMD-17-02-2-0006 from the Department of theArmy.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to the fields of organtransplantation and reconstructive surgery, and to the new field oftissue engineering. More specifically, the present invention defines anew method and materials for providing a compact microfluidic systemcapable of filtering impurities and waste products from the blood streamto treat patients suffering from damaged, malfunctioning or failingvital organs, such as the kidney and liver.

2. Description of the Related Art

There are two principal therapeutic avenues for patients suffering fromdiseased, malfunctioning or failing vital organs responsible for bloodfiltration. One of these avenues involves organ assistance devices, suchas the use of hemodialysis circuits in the renal unit of hospitals, orbridge therapy for liver failure such as the ELAD (Liver Assist Device).In the case of kidney dialysis, patients typically undergo 3 4-hourhemodialysis treatments per week in the clinic, each involving a trip tothe clinic and a process in which the patient is connected to a largepiece of equipment which filters waste products such as urea andcreatinine from the blood stream while maintaining electrolyte, glucoseand protein balances.

These treatments, while effective at sustaining life for ESRD (End-StageRenal Disease) patients, are highly invasive, and are limited ineffectiveness due to the non-physiological concentration profile ofwaste and impurities in the bloodstream. Namely, the concentration ofurea, for example, becomes elevated well beyond levels in healthypatients for the 2-3 days between treatments, and is then lowered veryrapidly during dialysis. These drastic excursions in concentration leadto complications and distress in dialysis patients, and thepsychological impact of dialysis is associated with a sharp increase insuicide rates among the patient population. Most significantly, thelong-term prognosis for ESRD patients on dialysis is poor, with 5-yearsurvival rates of less than 20%.

The cost of these treatments is staggering, totaling approximately $12Billion per year for the roughly 300,000 ESRD patients, or $40,000 peryear per patient. For patients with liver failure, liver assist devicesprovide only bridge therapy, perhaps a few weeks at best, until areplacement liver is available.

The second avenue of treatment for patients with failing organs such asliver and kidney is transplantation, in which a donor organ is implantedinto the patient from a variety of sources. These sources includecadaveric organs, which are in extremely limited supply, and thereforethe number of patients on the waiting list for a vital organ isapproaching 100,000 in the United States. Organ rejection by therecipient's immune system represents a huge challenge for the field oftransplant medicine, because it severely limits the potential donorpool. Even when the donor is a match, recipients are consigned to alifetime of immunosuppressive drugs, which are extremely expensive andare associated with a host of severe side effects. Other sources fordonor tissue and organs are living donor transplants, which in the caseof the kidney involve one organ from a donor with two healthy kidneys,or split liver transplants in which part of the liver of a healthypatient is transplanted into the recipient. Often involving familymembers, these transplants are typically safe for the donor but have ledto well-documented cases in which previously healthy donors sufferedlethal complications following transplant surgery.

Avenues beyond these two involve experimental procedures not yet readyfor wide clinical practice. These include the use of artificialmechanical organs, such as the artificial fully implantable heart,biohybrid organs involving combinations of mechanical/artificialmaterials and devices and living cells and tissues, and fully naturaltissue engineered organs which replace function.

The principal disadvantages of the two general approaches describedabove relate to the insufficient replacement of physiological organfunction without serious limitations or complications. In the case ofrenal assist devices, specifically, the invasive, complex anddiscontinuous nature of the treatments limit their therapeutic value,because they do not provide patients with benefits concomitant with ahealthy pair of kidneys. These disadvantages can be understood as beingassociated with limitations in the technology which insufficientlyreproduce organ function, and limitations associated with cost,complexity and accessibility. The former set of challenges can beaddressed by advances in dialysis involving either acellular processes(superior filtration, hemocompatibility, etc.) or cell-based processes(improvements in the resorption circuit which returns desired bloodcomponents to the body following ultrafiltration). The latter set ofchallenges relates to the fact that dialysis treatments are costly andlabor-intensive, require frequent visits to the clinic and large,complex machines, and are not continuous because of the need forcentralized dialysis clinics often distant from their patients.

Compact organ assist devices with continuous filtration that isphysiologic in nature would provide enormous patient benefit. Moreover,a wearable, continuous device will reduce costs and labor associatedwith treatment, and will eliminate most visits to the clinic except formaintenance and monitoring. Accordingly, there is a need for improvedsystems.

SUMMARY OF THE INVENTION

The present invention provides the design, materials, fabrication andassembly processes to construct and implement a vital organ assist oreven replacement device that overcomes the problems discussed above aswell as other obstacles known in the art.

In particular, the present invention provides the design, materials,fabrication and assembly processes to construct and implement amicrofabricated system to replace the blood filtering function of avital organ such as the liver or kidney.

In one embodiment, the present invention provides an apparatus whichduplicates the functionality of a physiological system, which includesfirst and second layers, each defining upper and lower surfaces. Inspecific embodiments, each layer can comprise a mold. A semi-permeablemembrane can be secured to the first and second molds such that theupper surface of the membrane is secured adjacent to the lower surfaceof the first mold and the lower surface of the membrane is securedadjacent to the upper surface of the second mold.

In another embodiment, the apparatus is organized into athree-dimensional structure comprised of multiple two-dimensionallayers, arranged in a repeating fashion, and stacked vertically in atotal stack of at least 8 layers (e.g., stacks of bi-layers, eachbi-layer consisting of an upper and lower surface). The presentinvention can comprise between about 50 and 2000 layers, more preferablybetween about 100 and 1000 layers and most preferably about 500 layers.

In yet another embodiment, the first and/or second molds can optionallyinclude flow control patterns, such as interconnected microchannels cutinto the mold, or disposed on a surface thereof. As used herein, theterm “flow control pattern” refers to any feature capable of affectingflow, e.g., limiting or directing fluid flow, ranging fromtwo-dimensional surface patterns to three-dimensional features such asposts, walls, channels or other raised structures. The flow controlpattern can enhance diffusion and convection, among other things. Thepatterns in the first mold can be identical or non-identical to thepattern in the second mold. The pattern in the upper surface of themolds can be identical or non-identical to the pattern in the lowersurface.

The apparatus can further comprise nutrient supply and excretion removallines in fluid communication with the apparatus, pumping means forcirculating fluid through the apparatus.

In a specific embodiment, the present invention provides an apparatuswhich duplicates the functionality of a physiological system comprisinga first mold, a semi-permeable membrane, a second mold and a pumpingmeans, wherein the first mold is fastened to the second mold and thesemi-permeable membrane is disposed between the first and second molds,and wherein the first and/or second molds have means defining flowcontrol patterns, and a pumping means for circulating fluid through thedevice.

In another specific embodiment, the flow control patterns can formfluidic chambers, supported by posts or walls. The fluidic chambers canbe modeled after blood vessels, and can be from about 5 μm (small bloodvessel dimension) in width and height to about 100 to 900 μm in widthand height.

In yet another specific embodiment, the flow control patterns can formmicrochannels. Microchannels of the invention can be various sizes, forexample, ranging from about 5 μm to about 5 mm in width and height, andextend longitudinally or latitudinally through the mold. The patterningof the microchannels can be controlled to form a microvascular network.The microchannels can be connected beginning from one or more inlets,expanding into more channels, and then converging back into one or moreoutlets.

In yet another specific embodiment, the first mold can comprise amicrovascular network layer and the second mold can comprise aparenchymal layer having parenchymal cells. “Parenchymal cells” includethe functional elements of an organ, as distinguished from the frameworkor stroma. Parenchymal cells can include but are not limited to smoothor skeletal muscle cells, myocytes, fibroblasts, chondrocytes,adipocytes, fibromyoblasts, ectodermal cells, including ductile and skincells, hepatocytes, kidney cells, liver cells, cardiac cells, pancreaticislet cells, cells present in the intestine, and other parenchymalcells, osteoblasts and other cells forming bone or cartilage, andhematopoietic cells.

In yet another specific embodiment, the present invention provides anapparatus for the filtration of small molecules, comprising a firstmold, a semi-permeable membrane, a second mold and a pumping means,wherein the first mold comprises a microvascular network, the secondmold comprises parenchymal cells and the pumping means circulates fluidthrough the apparatus such that small molecules are removed from themicrovascular network and passed to the parenchymal cells.

In other embodiments, the apparatus is acellular. In one embodiment,where the apparatus is acellular, the supply lines can be connected to arehydration system. The rehydration system can comprise proximal tubulereabsorptive units of the kidney. Renal filtration involves diffusionand convection processes which result in the removal of importantphysiologic electrolytes (e.g., calcium, potassium and sodium), andproteins (e.g., the “middle molecules”), in addition to quantities ofwaste products (e.g., urea and creatinine) and water. Therefore, bloodexiting the filtration portion of the kidney contains sub-optimalconcentrations of these critical biomolecules. In this embodiment, themicrofabricated filtration unit described herein is serially connectedto a cell-based reabsorption unit which performs the physiologicfunction of restoring the concentration of electrolytes and otherimportant biomolecules to desired levels once the blood has passedthrough the filtration device of the present invention. An engineeredreabsorptive unit connected with a system constructed in accordance withthe present invention can utilize cell function (i.e., proximal tubulecells of the kidney) or other known means to restore biomoleculeconcentrations to physiologic levels.

The surfaces of the molds are biocompatible can include a coating on themicrochannels that promotes cell adhesion to the apparatus. The surfacesare preferably hemocompatible, or treated to promote hemocompatibilityby, for example, the application of a hemocompatible film thereto orendothelialization of the surfaces. Blood clot-preventing compounds suchas heparin can also be used to further facilitate the uninhibited flowof blood and long-term operation of the device, among other things.

In one embodiment, the membrane is made of a hemocompatible material.

Furthermore, the molds or membrane can include at least one growthfactor covalently linked thereto at least one of the molds. The membranecan be biodegradable and have pores of between about 0.01 and about 20μm. The molds can include through-holes, and may be fastened to themembrane or each other by a spin-glue process or a plasma bondingprocess, among other things.

The present invention is also directed to a method of fastening asemi-permeable membrane having an upper and an lower surface to apolymeric mold. The steps of such a method in accordance with thepresent invention can include: exposing the membrane and a polymericfilm to oxygen plasma to attach the membrane and film to each other;separating the polymeric film from the membrane; and exposing themembrane and the mold to oxygen plasma to attach the surface of themold.

This method may also include the step of exposing the membrane and asecond mold to oxygen plasma to attach the surface of the mold.

The present invention is also directed to a method of fastening asemi-permeable membrane having an upper and a lower surface to apolymeric mold that includes the steps of: exposing the surface of thepolymeric mold to the liquid state of the polymer used to form thepolymeric mold; spinning the polymeric mold with the polymer liquidthereon; bringing the membrane in contact with the surface of thepolymeric mold; and allowing the polymeric liquid in contact with themold and membrane to set.

In the aforementioned method, the step of allowing the polymeric liquidin contact with the mold and membrane to set can further includeelevating the surrounding temperature.

The systems and methods of the invention can be implanted into a subjectto supplement or replace the biological function of a tissue or organ.Alternatively, the systems and methods can remain ex vivo, serving asextracorporeal devices to supplement or replace biological function.

Examples of tissues and organs which can be fabricated using thesemethods include, but are not restricted to, organs currentlytransplanted such as heart, liver, pancreas, lung, kidney and intestine.Other tissues such as muscle, bone, breast, reproductive and neuraltissue could also be engineered.

These and other embodiments are disclosed or are obvious from andencompassed by, the following detailed description taken in conjunctionwith the figures as described below.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description, given by way of example, but notintended to limit the invention to specific embodiments described, maybe understood in conjunction with the accompanying Figures, incorporatedherein by reference, in which:

FIG. 1 is a schematic diagram of an exemplary organ assist orreplacement device constructed in accordance with the present invention;

FIG. 2 a is a schematic view of a microfluidic network formed on apolymer film according to an embodiment of the present invention;

FIG. 2 b is a closeup view of the area of FIG. 2 a designated by theletter “b,” illustrating a portion of the microfluidic network of FIG. 2a in detail;

FIG. 2 c is a closeup view of the area of FIG. 2 b designated by theletter “c,” illustrating a portion of the microfluidic network of FIG. 2a in detail;

FIG. 3 is a schematic view of a bilayer system, incorporating amicrofluidic network as shown in FIG. 2 a and disposed on a porousmembrane, in accordance with an embodiment of the present invention;

FIG. 4 is a schematic diagram of a single pass, countercurrent systemconstructed in accordance with an embodiment of the present inventionwhich includes mold layers, including microfluidic networks embeddedtherein, separated by a microporous membrane and illustrates the flow ofblood and dialysate streams through the system;

FIG. 5 is a graph depicting urea concentration vs. time at varyingflowrate conditions using polycarbonate membranes in exemplaryultrafiltration experiments using the system of FIG. 4;

FIG. 6 is a chart depicting normalized experimental urea clearanceobtained by exemplary ultrafiltration experiments using the system ofFIG. 4, and a comparison of the experimental urea clearance withpublished data from the reference: S. Brunet, M. Leblanc, D. Geadah, D.Parent, S. Courteau and J. Cardinal, “Diffusive and convective soluteclearances during continuous renal replacement therapy at variousdialysate and ultrafiltration flow rates,” Am. J Kidney Dis. 34 486-492(1999);

FIG. 7 is a schematic diagram illustrating a renal ultrafilitration andreabsorption device constructed in accordance with the present inventionillustrating, among other things, the flow of blood therein; and

FIG. 8 is a cross sectional schematic diagram of the device shown inFIG. 7.

FIG. 9 shows a sample vascular branching network pattern used forsilicon and pyrex wafer micromachining.

These and other features of the present invention will become morereadily apparent to those having ordinary skill in the art from thefollowing description of the preferred embodiments.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description of the present invention,references are made to the accompanying drawings which form a parthereof, and in which is shown by way of simplified schematicillustrations specific embodiments in which the invention may bepracticed. These drawings are not necessarily intended to accuratelyportray the entire system of the present invention, nor are theynecessarily intended to be accurate portrayals of the size or shape ofthe elements of a system constructed in accordance with the presentinvention. However, one skilled in the art will readily appreciate thatthese figures along with the description herein are sufficient to enablethose skilled in the art to practice the present invention.

Devices constructed in accordance with the present invention aredesigned to mimic proper anatomical and physiological conditions, andpreferably provide even flow distribution, minimized flow resistance anda maximized surface area for transfer of oxygen nutrients and waste.Thus, devices constructed in accordance with this invention anticipate,and/or compensate therefore, non-Newtonian blood rheology and itsmultiphase nature, capillary occlusions causing local pressure drops,uneven velocity profiles and hematocrit distributions, among otherthings. Devices of the invention can optionally include flow controlpatterns to enhance diffusion and convection, among other things. Flowcontrol patterns are known in the art, and described in U.S. Pat. Nos.6,811,752, 6,810,713, 6,808,522, 6,808,075 and 6,802,342; as well as inKhademhosseini A, et al. (2004) Analytical Chemistry 76 (13): 3675-3681;Wang H Z, et al. (2003) J. Micromechanics and Microengineering 13 (6):801-808; Kuksenok O, (2002) Physical Reviews E 65 (3): Art. No. 031502Part 1; Delamarche E, et al. (1997) Science 276 (5313): 779-781; StroockA D, Accounts of Chemical Research 36 (8): 597-604; Ng J M K, et al.(2002) Electrophoresis 23 (20): 3461-3473; and Stroock A D, (2002)Analytical Chemistry (20): 5306-5312, the contents each of which areincorporated herein by reference. Furthermore, the present inventionutilizes microfabrication techniques to construct a system which, inaddition to possessing the necessary features (e.g., capillary beds,nephrons, tissue, cultured cells, etc.) to duplicate the functionalityof a specified physiological system, is also on a size scale similar tothat physiological system.

The present disclosure provides the design, materials, fabrication andassembly processes to construct and implement a microfabricated systemto replace the blood filtering function of a vital organ, such as theliver or kidney. The device can contain cells of the organ and avascular network, with or without cells, or can be acellular. It shouldbe understood that the present disclosure provides exemplary andpreferred embodiments and uses of the present invention, and should notbe limited thereto.

Extracorporeal and Implantable Devices

Devices constructed in accordance with the present invention can beimplanted into a subject to supplement or replace the biologicalfunction of a tissue or organ. Alternatively, the invention can beadapted to comprise devices for uses in addition to the formation ofimplantable tissue. The devices can remain ex vivo, serving asextracorporeal devices to supplement or replace biological function. Asused herein, the term “biological function” refers to the structural,mechanical or metabolic activity of a tissue or organ. Extracorporealdevices of the present invention can comprise hybrid devices suitablefor both ex vivo and in vivo use. Any of the devices constructed inaccordance with the present invention may provide partial supportfunction, may extend the time between hospital treatments for patientson chronic organ support therapies, and can improve the quality of lifebetween hospital treatments.

Commercially available extracorporeal devices do not incorporate theprecise microfabrication capabilities offered by MEMS technology, andtherefore function is limited by the resolution limits of current hollowfiber and membrane fabrication methods. Insertion of MEMS technologyinto this domain will provide major benefits for hemofiltering, dialysisand other applications. For example, the designs can be adapted toproduce an extracorporeal renal dialysis device, an extracorporeal liverdevice, or an extracorporeal artificial lung device. Such devices may ormay not be supported with living cells loaded or seeded into the device.

Referring now to the drawings wherein like reference numerals identifysimilar structural features of the invention, there is illustrated inFIG. 1, a microfluidic device constructed in accordance with a specificembodiment of the present invention and designated generally by thereference numeral 10.

Microfluidic device 10 includes an inlet 12 and an outlet 14 in fluidcommunication with a support body 16. Support body 16 substantiallysupports, and preferably encapsulates, a microfluidic network thatenables device 10 to provide organ assist capabilities and is discussedin further detail herein below. Active devices that can provide flow andfiltration control and optimization, such as pumps, valves, electricfields, transport devices, etc., can also be employed with microfluidicdevice 10.

Standard procedures may be employed to attach tubing connections forinlet 12 and outlet 14 to device 10 and external locations. Preferably,the process involves the bonding of tubing sections using either polymerglue materials, tight-fit connections, plasma bonding, or other meansknown in the art.

With particular regard to plasma bonding, support body 16 preferablyincludes a protective capsule. This can be an additional or optionalstep, which can provide further structural rigidity, as well as a moreimplantation-friendly shape for a device constructed in accordance withthe present invention for such purpose, among other things. In such anembodiment, the material forming the capsule should be the same as thematerial from which the actual device is formed. This allows the two tounite into a single, continuous material when the capsule polymer hascompletely cured. The shape of the capsule is conferred by the mold fromwhich it is created. Preferably, it is of a generally ovoid shape withconnector tubes for inlet 12 and outlet 14 emerging from the tip of oneof the long ends. The mold can be either rigid or conformal, and eithersingle or multi-usage (i.e., the mold can be discarded after one moldingprocess or it can be used multiple times to form several bodies of likeshape).

Alternatively, balloons can be used as single-usage, conforming molds.The opening of a balloon is placed around the opening of a filtrationflask, and the balloon is allowed to hang in the flask. Vacuum is drawnfrom a secondary inlet to the flask, causing the balloon to inflate.When the desired size is reached, the vacuum is maintained at itscurrent pressure. Liquid polymer is poured to cover the remaining spaceand the top of the balloon is closed by means such as a string orsimilar closure. The polymer is allowed to cure and the balloon is thencut open to release the encased microfluidic network.

Another way to produce the capsule is to use a rigid, multi-usage moldwith the desired shape. In one embodiment, the mold is constructed fromtwo parts. A small hole is formed on the first or upper part of the moldto allow for polymer to be poured therein. One of the two longer sidesshould carry a small outlet hole for the connecting tubing. A thin layerof polymer is poured into the lower part of the mold and it is allowedto cure. The device is then positioned on a layer of polymer, and theconnecting tubing is threaded through the appropriate hole of the upperpart of the mold. The two parts are secured together by known means andthe encasing is filled with liquid polymer through the hole at the topof the upper part of the mold.

In addition, the encasing mold can be a rigid, single-usage containersuch as a beaker or similar piece of glassware. The process is similarto the multi-usage mold described above. However, the mold can besacrificed to release the device, which can prove to be an easier taskto accomplish than preserving and reconditioning a multi-usage mold.

Materials and Methods

A two-dimensional (x, y) mold can be fabricated from a substratematerial using high-resolution molding processes, such as micromachinedwafer technology, thick photoresist processes, or other techniques,optionally micromachined, small dimensioned channels (“microchannels”)can be patterned on the surface of the mold and connected for thecirculation of fluid through a microfluidic network. Microchannels cancomprise, for example, open-faced channels defined by walls extendingfrom a tissue-defining surface of the substrate.

Materials suitable for forming the device and microfluidic networkwithin support body 16 in accordance with the present inventionpreferably meet several criteria. First, such materials are preferablyamenable to the microfabrication and assembly techniques such as thosedescribed herein below, including replica molding and bonding processes.These materials are preferably biocompatible, and not prone to foulingby such things as biofilms, proteins or other biological materialsduring use. Additionally, such materials preferably do not invoke aninflammatory or an immune system response.

Materials suitable for use as the substrate for the mold fabricationinclude, but are not limited to, poly-dimethyl-siloxane (PDMS),poly-glycerol-sebacate (PGS), polylactic acid (PLA), poly-L-lactic acid(PLLA), poly-D-lactic acid (PDLA), polyglycolide, polyglycolic acid(PGA), polylactide-co-glycolide (PLGA), polydioxanone, polygluconate,polylactic acid-polyethylene oxide copolymers, modified cellulose,collagen, polyhydroxybutyrate, polyhydroxpriopionic acid,polyphosphoester, poly(alpha-hydroxy acid), polycaprolactone,polycarbonates, polyamides, polyanhydrides, polyamino acids,polyorthoesters, polyacetals, polycyanoacrylates, degradable urethanes,aliphatic polyesterspolyacrylates, polymethacrylate, acyl substitutedcellulose acetates, non-degradable polyurethanes, polystyrenes,polyvinyl chloride, polyvinyl flouride, polyvinyl imidazole,chlorosulphonated polyolifins, polyethylene oxide, polyvinyl alcohol,Teflon®, nylon silicon, and shape memory materials, such aspoly(styrene-block-butadiene), polynorbornene, hydrogels, metallicalloys, and oligo(ε-caprolactone)diol as switchingsegment/oligo(p-dioxyanone)diol as physical crosslink. Other suitablepolymers can be obtained by reference to The Polymer Handbook, 3rdedition (Wiley, N.Y., 1989). Combinations of these polymers may also beused.

In a preferred embodiment, polymers are selected based on the ability ofthe polymer to elicit the appropriate biological response from cells,for example, attachment, migration, proliferation and gene expression.

Solvents for most of the thermoplastic polymers disclosed herein areknown, for example, methylene chloride or other organic solvents.Organic and aqueous solvents for protein and polysaccharide polymers arealso known. The binder can be the same material as is used inconventional powder processing methods or can be designed to ultimatelyyield the same binder through chemical or physical changes that occur asa result of heating, photopolymerization, or catalysis.

Properties of the mold and/or polymer surface can be controlled andchanged to impart desirable properties through the inclusion ofmaterials on the mold or in polymer surface which alter cell attachment(e.g., by altering the surface charge or structure), porosity,flexibility or rigidity (which may be desirable to facilitate removal oftissue constructs). Moreover, advances in polymer chemistry can aid inthe mechanical tasks of lifting and folding as well as the biologictasks of adhesion and gene expression.

The preferred material for microfluidic devices of this embodiment isPDMS, which is a silicone rubber material which is moderatelybiocompatible and highly amenable to microfabrication and assembly. Thismaterial is not known for hemocompatibility, and therefore it istypically coated with materials such as collagen, Matrigel®, Vitrogen,or other substances which enhance biocompatibility.

In order to reduce clotting, the coated PDMS can be endothelialized toimpart the microfluidic network with the same anti-thrombotic qualitiesas those provided to blood vessels by the presence of the endothelium.Further steps may be taken by pre-filtering of the blood at the frontend of the device, either by removing blood components such asthrombocytes or by injecting compounds such as heparin to reduceclotting.

Alternative materials to PDMS for the structural component (e.g.,channels for vascular and dialysate compartments of a renal dialysisdevice) can include polymethylmethacrylate (PMMA), polyethylene, or evenbiodegradable materials such as polyLactic (co-glycolic) acid (PLGA) orpolyglycerol sebacate (PGS), among other things. Some of thesematerials, particularly PMMA and PGS, are known to be highlybiocompatible, as well as hemocompatible. The biodegradable propertiesof PLGA and PGS, for instance, will limit the useful life of the device,but may be acceptable for systems in which the device is replaced on aregular basis (e.g., monthly) for maintenance purposes.

The filtration membrane material is preferably selected with carebecause of the significant and direct contact of blood with the membraneduring the filtering process. Initial work in hemodialysis, forinstance, employed the use of cellulose fibers, but these materialsshowed a propensity for clotting in dialysis systems. More recently,materials such as PMMA, polysulfone (PS) and polyethersulfone (PES) havebeen used for the hemodialysis membrane, with generally far superiorresults. Accordingly, the membrane can be made of a biologicallycompatible, nondegradable material such as cellulose,PolyDiMethylSiloxane (PDMS), PolyMethylMethacrylate (PMMA),PolyEtherSulfone (PES), PolySulfone (PS), PolyCarbonate (PC), or from adegradable material such as PLGA, PolyCaproLactone (PCL) or Biorubber,but the invention is not so limited.

Some exemplary devices constructed in accordance with the subjectinvention have used PDMS as the structural material of the microfluidicdevice while the membranes have been either polycarbonate (PC) or PES.The PC membrane has been used however it is not believed to haveenhanced biocompatibility or hemocompatibility. For a presentlypreferred embodiment, the structural material is selected fromendothelialized PDMS, PGS or PMMA, or a combination thereof, with themembrane being either PES or PMMA, or a combination thereof.

Some exemplary, non-limiting fabrication methods for manufacturingmicrofluidic networks for use with a device in accordance with thepresent invention are discussed below. In particular, polymer substrateshaving microfluidic networks thereon have been constructed usingdouble-sided molding techniques. In conventional soft photolithography,a silicon wafer is first processed with traditional micromachiningtechniques to carry a certain pattern. The wafer is placed in a petridish with the pattern facing upwards and the polymer in its liquid,non-crosslinked form is poured over the silicon mold. The polymerconforms to the shape of the mold and, with the help of heat or light,is converted to its solid, cross-linked state. The double-sided moldingtechnique uses two silicon molds and sandwiches the polymer in betweenthe two.

Materials other than silicon may also be used, however, one otherconsideration in this embodiment is that typical 500 μm thick siliconwafers may not provide sufficient mechanical strength for allapplications and embodiments in accordance with the present invention.This is because, after the polymer has set, it becomes difficult toseparate the wafer-polymer-wafer sandwich without breaking the siliconmolds. Therefore the use of thicker silicon wafers is preferred, suchas, for example, 700 μm, 1 mm, 1.5 mm, or even thick glass wafers may beused to ensure safe separation of the molds from the cured polymer.

The two mold wafers may be fabricated using either conventional bulksilicon processing, such as described in the related, commonly assignedapplication, U.S. patent application Ser. No. 10/187,247. Alternatively,an epoxy resin process, which is also described in the aforementionedApplication, can be used in which a thick photoresist directly serves asthe mold and silicon micromachining is not involved. The aforementionedpatent application is incorporated herein by reference.

The molds can carry the same or different patterns. Each mold is placedon a small pedestal, which sits in a large petri dish. The radius of thepetri dish should be greater than the radius of the silicon mold tocollect excess of polymer dripping from the sides of the mold. Thepedestal can range from a small petri dish to a metallic stand. The keyfeature is that the radius of the pedestal should be sufficientlysmaller than the radius of the silicon wafer, and the pedestal must betall enough to allow for polymer poured in excess of the capacity of themold surface to flow freely off the surface without trapping the mold inthe petri dish after it has cured.

Spacers may be applied to one of the two molds. The spacers are thin,uniformly flat objects that will keep the two molds apart from eachother and allow a polymer layer of uniform thickness to go between them.They control the thickness of the resulting polymer layer. A preferredembodiment utilizes four washers (e.g., Rockford 508 washers) with ameasured thickness of 1.2 mm+/−0.015 mm. Alternatively, one may deploysmall silicon wafer pieces, bringing the thickness of the mold layerdown to 500 μm. It is preferably that the spacers does not prevent thepolymer from flowing radially away from the mold as the two molds arebrought together. It is also preferably that the spacer is placed onmold “dead-space”, which bears no raised features. Washers may be usedto ensure uniform separation between the two molds across the entirearea of the silicon wafer.

In the next step, the polymer is poured over the mold. Roughly 15-20 mLof polymer is sufficient to completely cover the mold. After letting themolds settle for a sufficient period to ensure complete coverage, bothare placed in a vacuum chamber. A vacuum is then drawn, and the moldsdegas for about one hour. This removes all the microbubbles from thepolymer, which may have either originated from mixing the polymer withthe curing agent, or were trapped in the features of the mold whenpouring the polymer over them.

After some time has passed, (e.g., about one hour) the molds are takenout of the vacuum. The mold is then lifted without the spacers, andquickly flipped so that its features and the polymer face downwards. Itcan be positioned over the mold with the washers. The molds are thenplaced proximate to one another, in that the end of the upper mold issituated next the respective end of the lower mold so that the siliconsurface makes contact with the washer. The upper mold is then slowlylowered so that the two polymer layers come in complete contact witheach other. A gentle force is applied to push the excess polymer out andcomplete the sandwich.

The large petri dish carrying the pedestal, mold and polymer mold layeris placed in an oven at a temperature of about 65° C. for about 20minutes. Because of the minute thickness of the polymer compared to thesurface area of the silicon wafer this time is sufficient for completecuring. The petri dish is then taken out of the oven and allowed tocool.

The next step is to detach the two molds from the polymer mold layer. Avery thin, blunt object, such as flat spatula, is used as a wedge in theplane between the silicon and the polymer across the whole circumferenceof the mold, on both molds. The spatula can be inserted just a fewmillimeters to sufficiently ensure release. It is critical to completelyseparate the washers from the molds on both sides because that is wherethe highest stress concentration takes place, and where the mold layeris most likely to tear upon release. Insertion of the spatula betweenthe top mold and the washer along with a gentle, constant force for afew seconds, is the preferred method for accomplishing this task. Thissame process is then repeated on all spacers up until the top mold haslifted off from the polymer.

The same process is then repeated for the lower mold. Note that theorder of starting with the top mold and following with the lower one isimportant to ensure separation without breaking the molds or tearing themold layer. An example of a polymer mold layer 18 having pluralities ofmicrovascular networks 20 formed thereon by the microfabricationtechniques of the present invention described herein is shown in FIGS. 2a-c.

Membrane

A filtration membrane can be used to separate the first mold from thesecond mold of the present invention. Preferably, the membrane issemi-permeable and the pore size of the membrane is smaller than thecell diameters, thus, cells will not be able to pass through (i.e., alow permeability for animal cells), while low molecular weight nutrientsand fluids can pass through (i.e., a high permeability for nutrients),thereby providing adequate cell-to-cell signaling. Cell sizes vary butin general, they are in the range of microns. For example, a red bloodcell has a diameter of 8 μm. Preferably, the average membrane pore sizeis on a submicron-scale to ensure effective screening of the cells.

Semi-permeable membranes of the present invention comprise a wide arrayof different membrane types and morphologies, which can be classified asfollows:

-   -   (1) Track-etch membranes consisting of cylindrical through-holes        in a dense polymer matrix. These membranes are typically made by        ion-etching; or    -   (2) Fibrous membranes made by various deposition techniques of        polymeric fibers. While these membranes do not have a        well-defined pore topology, production methods have been        sufficiently refined so that fibrous membranes have specific        molecular weight cut-offs.

Track-etch type membranes are preferred, as they limit the fluid motionin one direction. Preferably, fluid motion is in the vertical direction.Fibrous membranes permit fluid motion both laterally and vertically.

In the exemplary embodiment discussed herein, once mold layers 18 havebeen fabricated, they are attached to a porous filtration membrane 22,an example of which is shown in FIG. 3. Plasma bonding is one commonlyemployed procedure that accomplishes polymer-to-polymer bonding forfilms such as polydimethylsiloxane (PDMS). Plasma bonding is awell-known process for modifying the surface of PDMS to increase thedensity of hydroxyl groups and the hydrophilicity of the material, whichtends towards a more hydrophobic behavior without plasma treatment.Typical plasma parameters include the use of pure oxygen gas, flowing ina vacuum oven at a pressure of about 200 mTorr, for periods of about30-60 seconds and power levels of roughly 50-100 Watts. The plasmatreatment is used to expose the surfaces of the layers to be bonded.

The first step is to expose the membrane and a blank piece of PDMS tooxygen plasma. Next, the membrane is attached to the blank piece ofPDMS. Once the two surfaces have been attached together, the membrane ispeeled from the blank PDMS. The membrane is then exposed to oxygenplasma again, along with a layer of PDMS with microchannels, and thesetwo pieces are attached together. Finally, the membrane/microchannelsandwich and the opposing microchannel layer are exposed to oxygenplasma and then attached together, forming the mold layer with thesemipermeable membrane.

The spin-glue process is a viable alternative to the plasma bondingtechnique and achieves polymer-to-membrane bonding. In this process, apolymer mold layer 18 (or single layer) is positioned with the sideholding the design of interest upwards. A small portion (about 1-2 ml)of the liquid state of the same polymer the mold layer 18 is made of ispoured onto the mold layer 18. This is counterintuitive since thearchitectural features of interest (e.g., microfluidic channels) areburied under the liquid polymer “glue”.

The mold layer 18 is then positioned on a spinner chuck and spun for 1minute at a set speed in the range of about 2000 rpm to about 3500 rpm.Spinning provides a conformal coating over the entire top surface of themold layer 18, while exposing all the channels previously buried underthe glue. The spin speed defines the thickness of the glue. A spin curve(i.e., what spin speed corresponds to what thickness) can be readilyestablished.

Mold layer 18 is taken out of the spinner and put on a flat surfacecovered with laboratory wipes. Membrane 22 (or another layer) is slowlybrought in proximity with mold layer 18. One can either make contact byhand, or gently release membrane 22 in very close proximity to moldlayer 18. With pressure from the center of mold layer 18 to theperiphery, membrane 22 is gently contacted to ensure it contactseverywhere with the polymer. Care should be taken not to apply too muchforce, which would cause membrane 22 to touch down at the bottom of thechannels, pick up glue and potentially occlude.

The polymer glue needs to set, and thus, the device can be left at roomtemperature for approximately two hours or put in an oven at about 65°C. for about five minutes, among other things. However, in using thelatter technique, buckling of the device may be observed. This isbecause the polymer expands more than membrane 22 when heated. This canbe advantageous, as a method of quality control, that is, if buckling isobserved then the polymer and membrane 22 have been successfully bondedto each other. Buckling helps relax the stress produced by thedifferential expansion of the two materials upon heating only if the twomaterials are tightly bonded to each other.

The same process may be used as many times as necessary to bond all moldlayers 18 to membranes 22 and to each other, thus creating a multilayerdevice. Preferably, mold layer 18 on which glue has been spun on needsto remain with the glue facing upwards, and the layer/membrane withoutthe glue is preferably facing downward.

Mathematical Modeling for Devices of the Present Invention

The first step in this modeling method is to create a hypothetical“mesh” depicting the device. Once the mesh is constructed, time-varyingbehavior is modeled in a series of discrete timesteps. At each timestep,three sets of calculations are made. First, the boundary conditions andconcentration distribution are used to calculate solvent velocitiesthroughout the device. Second, the solvent velocities are used todetermine the solute fluxes. Third, the solute fluxes are used to updatethe concentration distribution. The next timestep is then started bycalculating the solvent velocities from the boundary conditions and themodified concentration distribution.

An orthogonal mesh is created, filling the space of the device. The meshconsists of a set of nodes, each specifying an (x,y,z) location, and aset of vessels. Each vessel connects two nodes and is specified by thosetwo nodes. The mesh spacing is uniform.

Inlets and outlets to the device are included by defining appropriatenodes as inlet and outlet nodes, and their associated vessels as inletand outlet vessels. Inlets have specified solvent flow rates and outletsallow solvent and solutes to flow out of the device.

Each vessel is assigned a set of conductances L₁, L₂, L₃, and L₄representing the mass transport properties of the device in the regionof that vessel. These conductances will be discussed further in thefollowing sections. An initial concentration distribution is specifiedby assigning an initial concentration value at each node.

Calculation of Solvent Fluxes

The solvent velocity between any two points can be calculated knowingthe pressures and concentrations at those two points, and theconductances between the points. Solvent flow has two components,convection and osmosis. Convection contributes a fluxΦ_(C) =L ₁(P ₁ −P ₂),  (Eq. 1)where L₁ is the hydraulic permeability between the two points and P₁ andP₂ are the pressures at the first and second point, respectively. Thehydraulic permeability can be calculated from geometry: if the pointsare separated by porous material, L₁ is representative of the Darcy flowthrough the material. If the points are separated by a duct, such as acircular vessel or rectangular vessel, L₁ represents the laminar flowsolution of the duct. Any conductance between two points is given by theconductance of the vessel connecting those points.

The osmotic contribution to the flux is

$\begin{matrix}{{\Phi_{O\; 5} = {\sum\limits_{j = 1}^{N}{\sigma_{j}L_{1}{{RT}\left( {C_{j\; 2} - C_{j\; 1}} \right)}}}},} & \left( {{Eq}.\mspace{14mu} 2} \right)\end{matrix}$where σ₁ is the reflection coefficient of the material to the solute j,R is the universal gas constant, T is the absolute temperature, andC_(j1) and C_(j2) are the concentrations of solute j at the first andsecond point, respectively. We are summing the effects of N solutes.

The total volumetric flux of the solvent is the sum of the convectiveand osmotic components,

$\begin{matrix}{\Phi_{V} = {{L_{1}\left( {P_{1} - P_{2}} \right)} + {\sum\limits_{j = 1}^{N}{\sigma_{j}L_{1}{{{RT}\left( {C_{j\; 2} - C_{j\; 1}} \right)}.}}}}} & \left( {{Eq}.\mspace{14mu} 3} \right)\end{matrix}$

This equation cannot be used to directly calculate the fluxes since thepressures are unknown. The flux must be converted to flow rate q bymultiplying by an area,q=A_(c)Φ_(V),  (Eq. 4)where A_(c) is an appropriate area, the mesh spacing squared. Flow isconserved through any intersection of vessels, so continuity can beapplied to cancel the flow rates and create a matrix equation where thepressures are the only unknowns,[L ₁ A _(c) ][P]=[L ₂ ΔCA _(c) ]+[BC],  (Eq. 5)where [L₁A_(c)] is a nodal matrix describing the connectivity of themesh, [P] is a vector of the unknown node pressures, [L₂ΔCA_(c)] avector describing the osmotic effects, and [BC] is a vector describingflowrate boundary conditions. Internal forced or pumped flows can alsobe included in [BC]. If there are K nodes, the matrix is (K×K) and thevectors are all (K×1). This is a parabolic system of equations and canbe solved by LU factorization to compute the unknown pressures. Then Eq.3 can be used for each vessel to determine the solvent flux at thatvessel.

Solute flux is the sum of convective and diffusive terms. The convectiveflux of solvent j isΦ_(C) _(j) = C _(j)Φ_(V),  (Eq. 6)where C _(j) is an average concentration between points 1 and 2 and thesolvent flux has been calculated above.

The diffuse flux is given by Fick's Law,Φ_(D) _(j) =D _(j)(C _(j1) −C _(j2)),  (Eq. 7)where D_(j) is the diffusion coefficient of solute j in the materialbetween points 1 and 2.

Total volumetric solute flux is a sum of the convective and diffusiveterms,Φ_(j) = C _(j)Φ_(V) +D _(j)(C ₁ −C ₂)  (Eq. 8)The solute fluxes can be calculated directly for each vessel once theconcentrations and solvent fluxes are known.

Update of Concentrations

Concentration of solvent j at any node changes in time as described by

$\begin{matrix}{{{\frac{\mathbb{d}C_{j}}{\mathbb{d}t} + {U_{j}\frac{\mathbb{d}C_{j}}{\mathbb{d}x}}} = 0},} & \left( {{Eq}.\mspace{14mu} 9} \right)\end{matrix}$where U is the solvent speed, equal to Φ_(j)/C_(j) This equation isdiscretized on the mesh so the concentration at a node, at any timet+Δt, can be calculated from the concentrations and fluxes in the nodesand vessels around it. With U_(j) varying in space, this equation is avariable-coefficient linear hyperbolic equation known as the ColorEquation. Care must be taken to use a method that does not introducenumerical diffusion to the solution. Here, a high-resolution Gudunovmethod with Superbee flux limiting is used. This method is extended touse in three dimensions by a subinterval method. This method is run forevery node, updating the concentrations throughout the device at eachtimestep.

Iteration

Once the concentration has been updated, the simulation returns to thefirst step. The vector [L₂ΔCA_(c)] is modified by using the updatedconcentrations, and all three stages are repeated. The three stagestaken together represent one time step.

Initial Results

The above methods have been implemented in Matlab and run in test casesup to 200 nodes on a mesh representing a mold layer design with inletand outlet on each layer. The method is convergent in variouscombinations of convection, osmosis, diffusion, and forced flows.

EXAMPLES AND SPECIFIC EMBODIMENTS

Results obtained on single bilayer devices tested for ultrafiltration ofurea and creatinine are described in the following discussion. Singlebilayer devices were constructed using some or all of the techniquesdescribed in the above fabrication section.

A device 110 of the present invention is shown schematically in FIG. 4.Device 110 includes a first mold layer 118 a and a second layer 118 bseparated by a microporoous membrane 122. In one embodiment, the firstmold layer 118 a can comprise a microvascular network, includingmicrochannels that direct flow through chambers and conduits, and thesecond mold layer 118 b can comprise a parenchymal layer having cells.The term “microvascular network,” as used herein, refers to fluidicnetwork modeled after a physiologic vasculature, such as a capillarynetwork. The microvascular network either may or may not consist of anactual endothelium. In another embodiment, the mold layers are acellular(e.g., no cells are cultured within the layers).

In a specific embodiment, the microvascular network is comprised ofsmall and/or midsized vessels and connecting the vessels within onelayer to at least one additional layer with vertical links, as describedby PCT/US03/29880, filed on Sep. 23, 2003, the contents of which areincorporated herein by reference. In this embodiment, channels carryingblood (e.g., a vascular network) would be arranged proximally tochannels containing dialysate in the same layer, such that impurities inthe bloodstream would be filtered laterally across an interveningmembrane into the dialysate channel network, rather than vertically.Mass transport of the filtered blood products would occur through a setof “vertical pores” rather than through a horizontally positionedsemipermeable membrane. The geometries of the vertical pores can becontrolled to enable efficient hemofiltration.

In this system, countercurrent flows of blood and dialysate streams intoand out of device 110 are illustrated by arrows 124 and 126,respectively. Ultrafilitration flow through microporous membrane 122within device 110, from first mold layer 118 a to second mold layer 118b, is illustrated by arrows 128.

To study the ultrafiltration capabilities of a device having amicrovascular mold layer and a parenchymal layer, the clearances of ureaand creatinine from the vascular/“blood” stream 124 into theparenchymal/“dialysate” stream 126 were examined at varying flow ratesunder single-pass countercurrent conditions. For the purposes of thisexercise, the parenchymal layer as well as the microvascular mold layerwas empty, i.e., acellular. Microvasculature 120 a refers to amicrofluidic network modeled after a vascular network in order to mimicthe capillary networks developed for vascularized tissues as the flowpatter for the blood, among other things. The vascular fluid in flowstream 124 consisted of ultra-pure water containing dissolved urea andcreatinine at concentrations of 400 and 200 mg/dl respectively, whilethe parenchymal fluid of stream 126 consisted of only ultra-pure water.The urea and creatinine solutions were pumped through the vascular layer118 a containing the microvasculature 120 a and the ultra-purewater/“dialysate” was pumped through the parenchymal layer 118 b.

The flow-rate ratios of vascular flow (Q_(B)), parenchymal flow (Q_(D))and individual flow rates used for each solute were approximately at a2:1 ratio (Q_(B):Q_(D)) at 0.9 and 2.0 ml/hr respectively, 1:1(Q_(B):Q_(D)) at 1.0 ml/hr, and 1:1 (Q_(B):Q_(D)) at 2.0 ml/hr. In anincubator at 37° C., a syringe pump was used to administer each fluidinto its respective layer, under conditions of countercurrent,single-pass flow.

As the fluids moved through their respective layers, samples from eachflow stream were taken at various time points, up to five hours, andanalyzed for final concentration levels. The temporal distribution ofurea and creatinine concentration in the vascular and dialysate flows(see FIG. 5) were used to determine solute clearances and solutereduction rates. Finally, the calculated clearance values for urea andcreatinine obtained here were normalized with respect to currenthemodialysis parameters, including overall surface area and flow rate,and compared with published clearance values for overall efficiency (seeFIG. 6).

The results of the ultrafiltration experiments illustrated promisingresults with regard to the clearance of uremic solutes (i.e., urea andcreatinine) from a vascular stream into a dialysate stream in thesemicro-fabricated devices, especially when compared to conventionalhemodialysis clearances. When the data is normalized and compared toconventional hemodialysis parameters, including total surface area forfiltration, total internal volume, and total flow rate through thesystem, these bilayer devices, such as that depicted in FIG. 4, show atwo-to-three fold improvement over current published urea and creatinineclearance data that is representative of the efficiency of currenthemodialysis therapies.

The concentration versus time data for urea and creatinine show slightlydifferent trends with respect to the dialysate-side clearances. However,both sets of data, suggest that an approximate 2:1 vascular:parenchymalflow rate ratio, where QB=0.9 ml/hr and QD=2.0 ml/hr, is the optimalratio for the clearance of both solutes, which is the ratio used inconventional hemodialysis. This can be attributed to the establishmentof a higher concentration gradient of solute between the vascular andparenchymal networks when the vascular fluid is allowed to remain indevice 110 longer, relative to the parenchymal fluid.

The normalized data for both urea and creatinine clearance show thatthese bilayer devices are significantly to moderately more efficient atclearing uremic solutes from an incoming vascular stream thanconventional hemodialysis membranes, with urea clearance at a 2:1 flowrate ratio showing the most drastic improvement.

As shown in FIGS. 7-8, an exemplary extracorporeal renal unit 210includes a mold layer 218 a having a vascular network 220 a disposedthereon for ultrafilitration, a first porous biocompatible membrane 222a adjacent thereto, a mold layer 218 b having a vascular network 220 bdisposed thereon, a second porous biocompatible membrane 222 b adjacentthereto, and a tubule chamber 230 positioned between membranes 222 a and222 b having renal proximal tubule cells 232 disposed therein for thereabsorption of electrolytes. Alternatively, human or animal cells otherthan renal cells may be cultured or secured in device instead of or inaddition to tubule cells in chamber 230 or another location withindevice 210.

Blood flow 224 enters device 210 and contacts mold layer 218 a.Ultrafiltrate blood flow 234, and ultrafilitration 228 through membrane222 a, are directed to chamber 230 where exposure to proximal tubulecells occurs. Reabsorption flow 236 from chamber 230 is drawn throughmembrane 222 b to mold layer 218 b, while treated blood (i.e.,ultrafiltrate and reabsorption) flow 238 and filtered blood/dialysateflow 226 exit device 210.

Having thus described in detail preferred embodiments of the presentinvention, it is to be understood that the invention defined by theappended claims is not to be limited to particular details set forth inthe above description, as many apparent variations thereof are possiblewithout departing from the spirit or scope of the present invention.

For example, devices with greater amounts of layers, such as betweenabout 50 and 2000 layers, more preferably between about 100 and 1000layers and most preferably about 500 layers stacked together, can beconstructed in accordance with the present invention and using theprocess techniques described above.

Also, alternate methods for fabricating a device in accordance with thepresent invention include the use of the assembly processes describedherein with rolling or folding schemes, rather than stacking methods, toprovide high-throughput systems capable of reproducing organ function.Other alternatives include the use of laser machining, roll machining,injection molding and other techniques for machining of polymers orother suitable materials to generate layers for these filtrationdevices.

Another set of alternative methods for generating blood filteringdevices in accordance with the present invention involve the use ofmonolithic structures rather than stacked sandwich structures withmembranes and fluidic layers, as is described in International PCTApplication US04/16059, filed on May 21, 2004, and incorporated hereinby reference. In such devices individual layers of the comprise channelshaving multiple cell types (e.g., organ-specific cells and a vascularsupply) divided by membrane. Each layer comprises channels dividedlongitudinally into two compartments by a centrally positioned membrane,with each compartment containing a different cell type.

In another embodiment, the device of the invention are augmented by theaddition of active microdevices, such as pumps, valves and sensors, tomonitor the performance and to actively contribute to the filtrationprocess by altering the flows, pressures, distribution of bloodcomponents, and other critical parameters to enhance filtration. Forexample, micropumps, microvalves and microsensors have been developedusing MEMS processes for a wide range of medical and non-medicalapplications, including drug delivery, bioanalysis, drug discovery andclinical diagnostics. Pumps, valves and sensors are well known in theart for use in in vivo applications in which both biocompatibility andhemocompatibility are factors, and therefore are suitable forintegration with devices of the present invention. In one embodiment,devices of the invention can modulate the filtration process topreferentially filter certain classes of blood components over othercomponents. For example, a renal assist device of the invention canpreferentially filter urea and creatinine while maintaining aphysiological concentration of electrolytes in the vascular network.This can be accomplished, for example, coupling the renal assist devicewith a pump which filters charged electrolytes differently than urea andcreatinine.

Further modifications and variations of the methods and devicesdescribed herein, other than, and including those described above, willbe obvious to those skilled in the art, and are intended to beencompassed by the following claims.

We claim:
 1. An apparatus which duplicates the functionality of aphysiological system, comprising: a) a first mold defining upper andlower surfaces, wherein the lower surface of the first mold includesacellular microchannels formed thereon to create a microvascular networkfor circulation of fluids, wherein the acellular microchannels begin atone or more inlets, serially branch into a large array of acellularmicrochannels, and then converge back into one or more acellularmicrochannels at one or more outlets; b) a second mold defining upperand lower surfaces, wherein the upper surface of the second moldincludes acellular fluidic microchannels formed thereon; and c) asemi-permeable membrane defining an upper surface and a lower surface,wherein the upper surface of the membrane is secured adjacent to thelower surface of the first mold and the lower surface of the membrane issecured adjacent to the upper surface of the second mold, wherein smallmolecules are filtered from fluid in the microvascular network of thefirst mold through the semi-permeable membrane to the acellular fluidicchambers of the second mold.
 2. The apparatus of claim 1, furthercomprising nutrient supply and excretion removal conduits in fluidcommunication with the apparatus.
 3. The apparatus of claim 2, furthercomprising pumping means for circulating fluid through the apparatus. 4.The apparatus of claim 1, further comprising additional molds stackedupon the first and second molds to form about 8 to about 2000 layers. 5.The apparatus of claim 1, wherein the semi-permeable membrane is made ofa material selected from the group consisting of cellulose,PolyDiMethylSiloxane, PolyMethylMethacrylate, PolyEtherSulfone,PolySulfone, PolyCarbonate, PolyLactide-co-Glycolide, PolyCaproLactoneand Biorubber.
 6. The apparatus of claim 1, wherein there is a patternof microchannels in each of the first and second molds and the patternin the first mold is identical to the pattern in the second mold.
 7. Theapparatus of claim 1, wherein there is a pattern of microchannels ineach of the first and second molds and the pattern in the first mold isnon-identical to the pattern in the second mold.
 8. The apparatus ofclaim 1, further comprising a coating on at least one surface thatincludes a blood clot-preventing compound.
 9. The apparatus of claim 1,wherein the semi-permeable membrane is biodegradable.
 10. The apparatusof claim 1, wherein the semi-permeable membrane has pores of betweenabout 0.01 and about 20 μm.
 11. The apparatus of claim 1, wherein atleast one of the molds comprises through-holes.
 12. The apparatus ofclaim 1, wherein the fluid is blood.
 13. The apparatus of claim 1,wherein the acellular microchannels are about 100 μm to about 900 μm inwidth and height.